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Ministry of Defence

Defence Standard 02-872 Part 3


Issue 1 Publication Date 02 December 2002

Procedures for First Level Nickel


Aluminium Bronze Castings
Part 3
Revalidation

Category 1

AMENDMENTS ISSUED SINCE PUBLICATION


AMD NO

DATE OF
ISSUE

TEXT AFFECTED

SIGNATURE &
DATE

Revision Note
This Issue of this Standard has been prepared to incorporate changes to text and presentation. The
technical content has been updated in line with current practice.
Historical Record
DPT1312

DEFENCE STANDARD 02-872


PROCEDURES FOR FIRST LEVEL NICKEL ALUMINIUM BRONZE CASTINGS
PART 3
ISSUE 1
REVALIDATION

This Defence Standard


is authorised for use in MOD contracts
by the Defence Procurement Agency
and the Warship Support Agency

Published By:
Defence Procurement Agency
An Executive Agency of the Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown St
Glasgow G2 8EX
1

DEF STAN 02-872 Pt 3 / Issue 1

SCOPE
1.

This specification is to be used for the revalidation of Submarine First Level & sea wetted
castings made of Nickel Aluminium Bronze manufactured to DGS 8520, DGS 348 or
Defence Standard 02-747 Part 1, 2 or 4 which have had service use involving contact with sea
water.

2.

Revalidation in accordance with this specification is to establish the extent of any selective
phase corrosion, the acceptability of any weld repairs and the wall thickness following final
dressing to remove corroded regions. This information will allow the Design Authority to
determine the suitability of the casting for future use. It is additional to the normal inspections
and tests applied to the Submarine First Level castings, e.g. radiography and surface dye
penetrant examinations.

3.

Part 1 of this Defence Standard covers the policy for the recording and updating of Nickel
Aluminium Bronze castings fitted in submarines to meet the First Level Quality Assurance
requirements in accordance with SSP 25.

4.

Part 2 of this Defence Standard is to be used for the validation of all Submarine First Level
castings made of Nickel Aluminium Bronze manufactured to Defence Standard 02-747 Part 1,
2 or 4. It is to be used to establish a baseline of data for any weld repairs, wall thickness
measurements and the integrity of the casting at manufacture.

5.

Part 4 of this Defence Standard is to be used for in-service inspections carried out outside of
the Long Overhaul Period.

FOREWORD
Sponsorship
1.

This Defence Standard (Def Stan) is sponsored by the Defence Procurement Agency,
Ministry of Defence.

2.

The complete Defence Standard 02-872 comprises of:


Procedures for First Level Nickel Aluminium Bronze castings.
Part 1:

Policy

Part 2:

Validation

Part 3:

Revalidation

Part 4:

Inspections Outside of Long Overhaul Period

3.

If it is found to be unsuitable for any particular requirement the MOD is to be informed in


writing of the circumstances.

4.

Any user of this Defence Standard either within MOD or in industry may propose an
amendment to it. Proposals for amendments that are not directly applicable to a particular
contract are to be made to the publishing authority identified on Page 1 and those directly
applicable to a particular contract are to be dealt with using existing procedures.

5.

No alteration is to be made to this Defence Standard except by the issue of an authorised


amendment.
2

DEF STAN 02-872 Pt 3 / Issue 1

6.

Unless otherwise stated, reference in this Defence Standard to approval, approved, authorised
or similar terms, means the MOD in writing.

7.

Any significant amendments that may be made to this Defence Standard at a later date will be
indicated by a vertical side line. Deletions will be indicated by 000 appearing at the end of the
line interval.

8.

Extracts from British Standards within this Defence Standard have been included with the
permission of the British Standards Institution.
Conditions of Release
General

9.

This Defence Standard has been devised solely for the use of the MOD, and its contractors in
the execution of contracts for the MOD. To the extent permitted by law, the MOD hereby
excludes all liability whatsoever and howsoever arising (including but without limitation,
liability resulting from negligence) for any loss or damage however caused when the Defence
Standard is used for any other purpose.

10.

This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.

11.

The Crown reserves the right to amend or modify the contents of this Defence Standard
without consulting or informing any holder.

MoD Tender or Contract Process


12.

This Defence Standard is the property of the Crown. Unless otherwise authorized in writing
by the MOD, it must be returned on completion of the contract, or submission of the tender, in
connection with which it is issued.

13.

When this Defence Standard is used in connection with a MOD tender or contract, the user is
to ensure that they are in possession of the appropriate version of each document, including
related documents, relevant to each particular tender or contract. Inquiries in this connection
may be made to the Authority named in the tender or contract.

14.

When Defence Standards are incorporated into MOD contracts, users are responsible for their
correct application and for complying with contractual and other statutory requirements.
Compliance with an Defence Standard does not of itself confer immunity from legal
obligations.
Categories of Naval Defence Standard

15.

The Category of the Naval Defence Standard has been determined using the following
criteria:
a)

Category 1. If not applied may have a Critical affect on the following:


Safety of the Vessel, its complement or third parties
Operational performance of the vessel, its systems or equipment.
3

DEF STAN 02-872 Pt 3 / Issue 1

b)

Category 2. If not applied may have a Significant affect on the following;


Safety of the Vessel, its complement or third parties
Operational performance of the vessel, its systems or equipment.
Through life costs and support.

c)

Category 3. If not applied may have a Minor affect on the following.


MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.

Related Documents
16.

In the tender and procurement processes the related documents in each Section and Annex A
can be obtained as follows:
a)

British Standards

British Standards Institution


389 Chiswick High Road,
London, W4 4AL.

b)

Defence Standards

Defence Procurement Agency


An Executive Agency of the MoD
UK Defence Standardization,
Kentigern House, 65 Brown Street,
Glasgow, G2 8EX

c)

Other documents

Tender or Contract Sponsor to advise

17.

All applications to Ministry Establishments for related documents are to quote the relevant
MOD Invitation to Tender or Contract Number and date, together with the sponsoring
Directorate and the Tender or Contract Sponsor.

18.

Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.

Health and Safety


Warning
19.

This Defence Standard may call for the use of processes, substances and procedures that may
be injurious to health if adequate precautions are not taken. It refers only to technical
suitability and in no way absolves either the supplier or any user from statutory obligations
relating to health and safety at any stage of manufacture or use. Where attention is drawn to
hazards, those quoted may not necessarily be exhaustive.

20.

This Defence Standard has been written and is to be used taking into account the policy
stipulated in JSP430: MOD Ship Safety Manual System Handbook.

DEF STAN 02-872 Pt 3 / Issue 1

Use of ARDROX 160 and silver nitrate solution


21.

Before using this Defence Standard in conjunction with Ardrox 160 and the silver nitrate
solution, users should make themselves familiar with the precautionary measures set out in
this Section.

22.

Care is to be taken to ensure that the silver nitrate etching solution does not come into contact
with the skin or eyes, e.g. a face mask and rubber gloves must be worn.

23.

Protective clothing should be worn and other measures taken as necessary in handling the
materials referred to in this Defence Standard.

24.

Ardrox 160 is a proprietary product and the manufacturers health and safety instructions must
be followed.
Additional Information
(There is no relevant information)

DEF STAN 02-872 Pt 3 / Issue 1


CONTENTS
Page No
TITLE PAGE

SCOPE

FOREWORD

Sponsorship

Conditions of Release

Categories of Defence Standard

Related Documents

Health and Safety

CONTENTS

SECTION

1.
1.1
1.2
1.3

GENERAL REQUIREMENTS
Selection of Castings for Revalidation
Identification
Pre-requisites for Revalidation

8
8
8
9

SECTION

2.
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3

CLEANING OF CASTINGS
General
Opening Up Inspection
Cleaning & General Etching
Cleaning Method 1
Cleaning Method 2
General Etching Method

10
10
10
10
11
11
11

SECTION

3.
3.1
3.2
3.3
3.3.1
3.3.2
3.4
3.5
3.6

ETCHING AND EXAMINATION FOR CORROSION


General
Visual Examination
Detection of Corrosion
Detailed Etching Method
Ultrasonic Examination
Removal of Corrosion
Post Dressing Thickness Gauging
Recording of Examination Results

12
12
12
12
13
13
13
13
14

DEF STAN 02-872 Pt 3 / Issue 1

SECTION

4.
4.1
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.6

ACCEPTANCE CRITERIA
Cleaning
Wall Thickness
90% Criterion
Finite Element Analysis (FEA) and Lifing
Handling of Rejected Components
Re-Stamping
Certification
Records

15
15
15
15
15
16
16
16
16

SECTION

5.
5.1
5.2
5.3
5.4
5.5
5.6
5.7

RECLAMATION OF REJECTED CASTINGS


Policy on Weld Repair
Options for Casting Repair
Procedure for Weld Repair
Inspections
Re-Stamping
Certification
Records

17
17
17
17
17
17
18
18

ANNEX A.

RELATED DOCUMENTS

19

ANNEX B.

DEFINITIONS AND ABBREVIATIONS

20

ANNEX C.

PROCUREMENT CHECK LIST

21

ANNEX D.

CASTING RECORD OF REVALIDATION INSPECTION

22

ANNEX E.

REVALIDATION CERTIFICATE FOR NAB CASTINGS

23

ANNEX F.

CHECK LIST FOR DOCUMENTS TO BE INCLUDED


IN QA PACK FOR REVALIDATED CASTINGS

24

ALPHABETICAL INDEX

25

DEF STAN 02-872 Pt 3 / Issue 1

1.

GENERAL REQUIREMENTS
Related Documents: Def Stan 824, Def Stan 02-872 part 2, DGS 8520, see also Annex A

1.1

a.

Extensive examinations have shown that the Nickel Aluminium Bronze (NAB)
castings used since the early 1960s are, to varying degrees, susceptible to normal and
selective phase attack by sea water which destroys the mechanical properties of the
material without any obvious change in the appearance of the materials' surface.

b.

To limit the effect of this corrosion problem, it is necessary to examine NAB castings
prior to fitting in critical positions, and to carry out periodic examinations during
their life. These examinations are termed 'Validation' and 'Revalidation' respectively.

Selection of Castings for Revalidation


a.

A number of 'Higher Risk' NAB castings will be selected by WSA for examination
during Docking Periods (DP) as considered necessary. Inspections are to be carried
out to the requirements of Part 4 of this Defence Standard. Reports of examination
are to be made to the Design Authority as early as possible to enable the results to be
assessed and necessary actions to be undertaken during the DP.

b.

At LOP(R) all NAB castings listed in the NAB Register are to be either revalidated
in accordance with Part 3 of this Defence Standard, or replaced with NAB castings
validated in accordance with Part 2 of this Defence Standard or Copper Nickel
Chromium castings to Def Stan 02-824. Repair by welding will not normally be
allowed on revalidation (see Section 5 of this Defence Standard).

c.

If at any time during the revalidation process, the LOP(R) Contractor believes that
revalidation is physically impossible or economically not viable for a casting Design
Authority endorsement is required before the casting is rejected.

d.

Non-critical castings (those not listed in the NAB Register) are to be replaced only
when defective.

NOTE: To ensure that the Design Authority is given sufficient time to answer individual
queries, it is essential that the Design Authority receives information on castings as early
as possible, including accurate detailed information on defects. The reason for rejecting the
casting must be clearly stated, and be supported with detailed information. Defect
information must as a minimum contain accurate positions, types, extent and depth of
corrosion, together with detailed sketches.
1.2

Identification
a.

Previously validated/revalidated castings should be stamped with a code which


uniquely identifies them. The code consists of the radiographic number which may
be preceded by the letters H or HA. The letters H and A indicate that the casting has
been heat-treated and weld repaired respectively. Castings manufactured to
specifications subsequent to DGS 8520 will have their specification indicated,
followed by letters VAL and the date. The letters VAL and the date show that the
casting has been previously validated/revalidated on the date shown.

b.

Where radiographs are preceded with other than H or HA such as UI they can be
linked to the H/HA number via the QC495.
8

DEF STAN 02-872 Pt 3 / Issue 1

1.3

Pre-Requisites for Revalidation


a.

A casting examination control facility is required at the repair source, together with a
register of properly trained personnel who have the necessary experience to carry out
the procedures described in this Defence Standard. The Design Authority will define
what level of training and experience is necessary.

b.

The Revalidation Contractor is to demonstrate to the Design Authority that


procedures necessary to control and document the application of this Defence
Standard are in place before work is carried out.

c.

The Quality Assurance (QA) documentation from previous validation or revalidation


is to be available to the personnel making the inspection. As a minimum these shall
include:(1) drawings with dimensions and wall thickness
(2) all non conformance documentation (concessions etc) affecting casting integrity
(3) validation or revalidation certificate
If available (4) casting wall thickness maps
(5) weld repair maps

NOTE: If the QA documentation in (1) to (3) is not available, the Design Authority is to
be informed of the component description and details stamped on the component e.g.
radiograph/unique number, validation/revalidation date. The Design Authority is to advise
action to be taken.
d.

Revalidation Contractors who find information on the castings which does not
correspond to that on the QA documentation are to refer to the Design Authority for
further action.

e.

Non Destructive Examination (NDE) methods such as ZIPSCAN must be formally


defined and approved by the Design Authority before use. Factors such as training,
limits, accuracy and archiving of results must be specified before approval to use
these techniques is granted.

WARNING: ZIPSCAN ~ Total reliability is not guaranteed under all conditions and until
a fully approved method is available these techniques must be restricted to use a detecting
corrosion with confirmation of corrosion depth verified by an etch and grind process.

DEF STAN 02-872 Pt 3 / Issue 1


2.

CLEANING OF CASTINGS
Related Documents: Def Stan 68-188, Def Stan 80-20, see also Annex A

2.1

General
a.

The sea water wetted surface of the castings will be covered with varying degrees of
biofouling, calcareous deposits and redeposited copper that can be difficult to
remove.

b.

Any cleaning processes used are not to be detrimental to the casting. Special care is
to be taken to protect machined surfaces. Approved methods of cleaning NAB
castings include:
i). Hydrojetting with or without entrained abrasives.
ii). Dry blasting with alumina grit.
iii). Chemical Dip.

2.2

2.3

c.

Metal will be removed with any blasting process and damage to the casting is to be
prevented. The nozzle must be kept moving at all times, i.e. castings should be swept
blast and machined surfaces must be masked.

d.

The casting is to be visually inspected for general condition and satisfactory


condition of seal faces and machined tolerances before the costly and time
consuming effort of removal of all surface redeposited copper by abrasion is carried
out. If at any stage the casting is deemed to be unsuitable for revalidation, the process
is to be stopped and Design Authority guidance is to be sought, as detailed in Clause
1.1, as to whether the casting should be rejected or revalidation is continued.

e.

Suitable methods of cleaning are described in Clauses 2.3.1 and 2.3.2. The
contractors cleaning procedure and the training of operators must have Design
Authority written approval.

f.

Cleaning of castings must be carried out by staff who are suitably experienced.

Opening Up Inspection
a.

The unique number stamped on the casting is to be read off and a check made to
ensure that it is listed in the NAB Register and that there are no concessions on the
casting that would make it undesirable to revalidate.

b.

Where it is impractical or undesirable to revalidate a casting it is to be removed and


replaced as per the requirements of Part 1 of this Defence Standard.

c.

It is important that data on the state of the casting when it is removed from service
and prior to cleaning is established. Photographs should be taken when considered
necessary to add value to the survey report.

Cleaning & General Etching


a.

The surfaces of the casting that have been in contact with sea water are to be cleaned
by an approved method, as described below. Cleaning Method 1 should be used to
remove all marine growth and surface corrosion products. This should be followed
by Cleaning Method 2 to provide clean, degreased surfaces for etching.
10

DEF STAN 02-872 Pt 3 / Issue 1


2.3.1

Cleaning Method 1
a.

The surfaces of the casting that have been in contact with sea water are to be cleaned
by an approved method to remove marine growth and surface corrosion products.
Approved methods of mechanically cleaning NAB castings include hydrojetting with
or without entrained abrasives and dry blasting with alumina grit.

b.

Blasted surfaces are then to be lightly abraded with an emery disc or flap wheel to
remove all surface redeposited copper where present. Note that the etching solution
used to detect selective phase corrosion will give a false indication if surface
redeposited copper is still present.
NOTE: The machined surfaces are to remain protected.

2.3.2

2.3.3

Cleaning Method 2
a.

The casting is to be degreased either in a hot water detergent or in a cold agitated


solvent to Def Stan 68-188 or similar approved alternative for between 30 minutes
and 1 hour, or as advised by the manufacturers instructions.

b.

After degreasing, the casting is to be washed in hot fresh water until the degreasing
solvent is removed.

c.

Paint can be removed by an additional dip in a chemical cleaner to Def Stan 80-20 or
similar approved alternative for up to 8 hours after which the casting must again be
washed, this time in cold water.

General Etching Method


a.

On completion of cleaning, the casting is to be dipped for between 1 and 10 minutes


in an approved brightening solution, e.g. Ardrox 160 (available under NSN 99 220
1162) or similar approved alternative. This process will etch the surface of the
casting, highlighting areas of weld repair, and selective phase corrosion, should these
exist. The solution must be sufficiently fresh not to contaminate the casting surface
with redeposited copper. After removal from the dip bath, the casting is to be
thoroughly washed in cold fresh water to remove all traces of the brightening
solution.

b.

In general, the appearance of the various exposed surfaces of the casting following
dipping in Ardrox 160 will be roughly as follows:
Weld metal
Parent Metal
HAZ Corrosion
Plug/Crevice Corrosion

c.

- Dark Grey or Black


- Mid Grey
- Greyish Green
- Copper Colour or Greyish Green

A suitably experienced person (See clause 1.3a) is to check that the casting is free
from surface redeposited copper before the etching and examination for corrosion
described in Section 3 is carried out. The suitably experienced person is to advise
when the brightening solution requires changing, e.g. if it causes re-deposition of
copper. See Defence Standard 02-341.

NOTE: Due to the toxicity of Ardrox 160, contractors may prefer to use an alternative
general etching chemical, e.g. ferric chloride. Where such a change is proposed, prior
approval should be obtained from the Design Authority.
11

DEF STAN 02-872 Pt 3 / Issue 1

3.

ETCHING AND EXAMINATION FOR CORROSION


Related Documents: Def Stan 02-872 Part 2, see also Annex A

3.1

3.2

3.3

General
a.

The castings require immersion in the Ardrox 160 solution prior to the examination
detailed in this Section to enable the location of the weld repairs and the areas of
plug/crevice corrosion to be established. It is only once these areas have been
identified that the more searching etching techniques can be applied. Experience of
re-validating NAB valve bodies has revealed that the Ardrox 160 etchant is unable to
detect selective phase attack in the form of a continuous uniform layer, rather than
the plug type attack normally associated with this form of corrosion. Only 10%
Silver Nitrate etchant is to be employed for the more detailed examination covered
by this Section of the specification. This is consistent with the method specified at
Clause 3.4b to ensure the complete removal of all corrosion.

b.

The main corrosion mechanism causing concern with NAB castings is selective
phase corrosion which occurs under crevices and biofouling (plug corrosion) or
around weld repairs in the heat affected zone (HAZ corrosion). Selective phase
corrosion can penetrate the thickness of the casting at up to 1.1 mm per year with no
apparent surface loss of metal. The purpose of the procedures described in this
Section is to detect and establish the depth of selective phase corrosion.

Visual Examination
a.

The detailed visual examination after the etching described in this Section is to be
carried out by staff meeting prerequisite in Clause 1.3a. The location of selective
phase corrosion will be around weld repairs and under biofouling and crevices. It is
imperative that all welds on seawater wetted and non wetted surfaces are identified
after general etching, referring to Clause 2.3.3b. Previous QA documentation is to be
consulted to assist locating these weld repairs which are to be identified on the
casting using a felt tip marker.

b.

Areas of plug and crevice corrosion are to be identified on the casting using a felt tip
marker.

Detection of Corrosion
a.

HAZ corrosion is typified by a narrow band of corrosion around weld repairs. The
surface must be dry abraded to a distance of at least 10mm all round the weld
typically with a flap wheel (80 grit) just prior to etching (i.e. within one hour). Welds
on non-wetted surfaces can have HAZ's extending to wetted surfaces. If there is any
doubt these are also need to be identified and the seawater wetted surface prepared
for etching.

b.

Areas of plug corrosion are visible following general etching (see Clause 2.3.3b) and
can be seen as dimples in the surface or patches of redeposited copper. To prepare
the surface for etching, the surface must be abraded to a smooth even finish, typically
with a flap wheel (80 grit), just prior to etching (i.e. within one hour).

12

DEF STAN 02-872 Pt 3 / Issue 1

3.3.1

3.3.2

3.4

3.5

Detailed Etching Method


a.

Areas of selective phase corrosion are to be identified by etching with fresh 10%
silver nitrate solution stored in a dark bottle to prevent deterioration by light. The
etch is preferably to be applied using a fine spray to moisten the metal surface.
Alternatively a soft brush may be used. Swabs may be used provided care is taken to
avoid contamination which can cause spurious results, (this usually means that swabs
are used only once on a single wipe). Etching is to be carried out within one hour of
dry abrading the surface, as the surface develops an oxide film resistant to etch
solutions after a period of time.

b.

The silver nitrate etch will reveal regions of selective phase corrosion which turn
black. This is caused by silver depositing on any redeposited copper within the
regions of selective phase corrosion. Note that care is required to ensure that all
general surface redeposited copper is removed as this will also turn black and can be
confused with selective phase corrosion.

c.

Wash the etched areas thoroughly with fresh water to remove the etching chemicals.

d.

Repeat etching will be required after removal of the corroded regions.

Ultrasonic Examination
a.

The use of NDE such as ultrasonic methods for measuring wall thickness must be
supported by written procedures to a specification approved by the Design Authority.

b.

Ultrasonic NDE methods, e.g. ZIPSCAN, have been used with limited success to
measure the depth of selective phase corrosion which has occurred at the HAZ. Total
reliability, however, is not guaranteed under all conditions and until a fully approved
reliable NDE method is available these techniques must be restricted to use as an aid
for detecting corrosion with confirmation of corrosion depth verified by an etch and
grind process.

Removal of Corrosion
a.

Thickness mapping of the surface is required prior to commencing any grinding


process. All areas where corrosion is present must be thickness gauged using
callipers or an approved ultrasonic method in accordance with Clause 3.3.2.

b.

Corroded areas identified in Clause 3.3 are to be ground out using suitable tooling,
e.g. tungsten carbide burrs or grinding wheels, until further etching shows no
corrosion indications remaining. Not more than 1mm depth of metal shall be
removed prior to repeat etching with silver nitrate.

c.

If corrosion removal has reduced the wall thickness to the minimum figure of 90% of
drawing final machined dimension and further corrosion still remains, the casting is
to be referred to the Design Authority for the suitability for life assessment to be
determined; refer to Clause 4.2.

Post Dressing Thickness Gauging


a.

All areas where corrosion was present must be thickness gauged using callipers or an
approved ultrasonic method in accordance with Clause 3.3.2.
13

DEF STAN 02-872 Pt 3 / Issue 1

b.
3.6

It is mandatory that the dimensions of all ground out areas are recorded as defined in
Clause 3.6.

Recording of Examination Results


a.

A full report of the examination is to be submitted to the Design Authority. This is to


include casting sketches showing the location of corrosion, referenced to the depth of
corrosion penetration and casting wall thickness.

b.

In addition, a Casting Record of Revalidation Inspection, an example of which is at


Annex D, should be filled in. A separate sheet should be filled in for each casting.
This is used to supply the information required to carry out life assessment. The
following information should be included in the Table:
(1)

The casting description, unique number and previous QA document number


shall be logged at the top of the table.

(2)

All weld repairs and other defects where corrosion has been removed using the
procedures in Clause 3.4 of this document are to be given a number which will
be marked on the casting using a felt tip marker and logged in column 1 of the
Table. Note that all areas of corrosion are to be logged, including any grooving
at 'O' seals. Grooving or pitting at 'O' seals is a special case to be referred to the
Design Authority.

(3)

Details of weld repairs on sea water wetted surfaces, obtained from previous
QA documentation, are to be entered in column 2 of the Table next to defects
identified in column 1. Note that some weld repairs may not have resulted in
corrosion but confirmation of this is required. A sketch or photograph of areas
of corrosion, with identification numbers as referenced in column 1 of the
Table, should accompany the Table. Gridded sketches for large headers, based
on Finite Element Analysis (FEA), can be obtained through the Design
Authority.

(4)

Grid based thickness scans for the larger NAB castings should be available
with the QA documentation in accordance with Part 2 of this Defence
Standard. If these are not available then general wall thicknesses should be
measured on a gridded sketch at a spacing to be agreed with the Design
Authority. The measurements should give sufficient detail to provide
confidence on the general wall thickness. For guidance the grid spacing will be
typically 70 mm to 100 mm.

(5)

On the castings, measure the maximum straight surface length 'A' in any one
direction and the maximum depth 'B' for each ground out defect and record
these on the Table in columns 4 and 5.

(6)

Using a calibrated ultrasonic probe or callipers, measure the thinnest wall


adjacent to the defect, i.e. measure the wall thickness prior to the grinding out
of the defect. This defect free wall thickness 'C' is to be recorded in column 6
of the Table. Subtracting the defect depth 'B' from this will give the remaining
wall thickness 'D', where D=(C-B), see column 7 of the Table. This can be
confirmed by measuring directly the remaining wall thickness 'D'.

(7)

Complete columns 8 to 10 in the Casting Record of Revalidation Inspection


Table.

14

DEF STAN 02-872 Pt 3 / Issue 1

4.

ACCEPTANCE CRITERIA
Related Documents: Def Stan 02-341, Def Stan 02-747 Parts 2 and 4, Def Stan 02-824, see
also Annex A

4.1

Cleaning
a.

The casting has been satisfactorily cleaned when all fouling and redeposited copper
has been removed. Acceptance must be confirmed by suitably experienced
personnel.

4.2

Wall Thickness

4.2.1

90% Criterion

4.2.2

a.

The 90% of the finished machined drawing wall thickness criterion is simple to use
and complies with the requirements of Defence Standard 02-747 Parts 2 and 4. If a
specified life is required refer to life assessment in Clause 4.2.2.

b.

All areas where corrosion was present must be thickness gauged to ensure that the
finished machined thickness given on the manufacturing drawing has not been
reduced by more than 10%.

c.

Castings whose thickness has been reduced by more than 10% below the drawing
thickness are to be REJECTED.

d.

REJECTED castings with minimum pressure retaining wall thickness greater than
14mm are to be referred to the Design Authority for suitability for life assessment to
be determined as identified in Clause 4.2.2.

e.

Complete columns 8 to 10 in the Casting Record of Revalidation Table, see Annex


D.

Finite Element Analysis (FEA) and Lifing


a.

It might be economic to carry out life assessment for rejected large castings to justify
a further commission or to calculate a maximum justified life. The decision is to be
made by the Design Authority whether the full extent of the corrosion should be
removed to provide the required information for life assessment.

b.

Life assessment methods developed include:(1) Probabilistic approach using NABWETLIFE, a MoD developed code
(2) Deterministic approach using FEA and Fracture Mechanics

c.

The probabilistic approach is more suited to thinner wall castings which are included
in the NABWETLIFE submarine specific database and will identify which castings
and the timescale for inspection.

d.

The deterministic approach is suitable for castings which are either not covered by
the probabilistic approach, i.e. those castings which are not included in the submarine
specific database, or for larger components where there are complex stress profiles
under shock conditions, e.g. major header castings.
15

DEF STAN 02-872 Pt 3 / Issue 1

Data requirements for the deterministic approach are as defined in the Casting Record of
Revalidation Inspection Table, Annex D. All corrosion must be completely removed using the
procedures in Section 3.
e.
4.3

4.4

Complete columns 8 to 10 in the Casting Record of Revalidation Inspection Table.

Handling of Rejected Components


a.

Rejected castings are to be referred to the Design Authority who will advise scrap,
life assessment or repair action. Reclamation will be in accordance with Section 5,
life assessment will be in accordance with Clause 4.2.2.

b.

All rejected castings, even those unsuitable for reclamation and life assessment, are
to be collated in one batch as appropriate and referred to the Design Authority who
may decide to authorise full removal of the corrosion by separate contract action so
as to provide useful data.

c.

Castings which fail revalidation and are beyond economic repair are to be replaced
with castings validated in accordance with Part 2 of this Defence Standard, a
previously revalidated casting to this part of this Defence Standard, or a Copper
Nickel Chromium casting to Def Stan 02-824.

Re-Stamping
a.

The suitably experienced personnel witnessing the stamping of the casting are to sign
the validation certificate. A line is to be stamped through the previous validation date
and the new date stamped as a suffix to the original number.

NOTE: Pressure castings are not to be stamped on the highly stressed region e.g. Critical
Test Regions of the castings. The stamping should be positioned on low stress areas as
indicated below:
i. Valve bodies - should be stamped at the edge of the cover flange or in the absence
of a prominent flange then as close to the cover position as possible. Failing this
another flange should be stamped, but stamping on hull flanges is to be avoided.
ii. Flange fittings - to be stamped on a flange edge.
iii. Unflanged fittings - to be stamped on an area that is thicker that the minimum
acceptable wall thickness.
4.5

Certification
a.

4.6

All castings that are free of corrosion, or have defects which have all been assessed
as safe in the Casting Record of Revalidation Inspection Table are to be re-stamped
in accordance with Clause 4.4, and issued with a Revalidation Certificate in the
format of Annex E.

Records
a.

A copy of the Revalidation Certificate, QA certificate of compliance and the full QA


records, as listed in Annex F, are to accompany the casting. These are to be held by
the Through Life Records Contractor when the casting is fitted to the vessel, and are
to be available for future revalidations.
16

DEF STAN 02-872 Pt 3 / Issue 1

b.

On completion of installation the original documents held by the supplier/


manufacturer are to be passed to the Through Life Records contractor to be held as
master Records.

NOTE: The records should be of a suitable quality for scanning purposes.

5.

RECLAMATION OF REJECTED CASTINGS


Related Documents: Def Stan 02-747 Parts 2 and 4, Def Stan 02-771, Def Stan 02-872 Part
2, see also Annex A

5.1

Policy on Weld Repair


a.

5.2

Options for Casting Repair


a.

5.3

5.4

5.5

Weld repair is not normally to be carried out to reclaim rejected castings. There may
however be occasions when weld repair might be considered an appropriate action to
take. If appropriate, weld repair will be approved by a production permit, issued by
the Design Authority. In these circumstances, the procedure in Clause 5.3 is to be
applied, provided the area is isolated and that the distortions caused by welding are
acceptable.

Alternative methods of reclamation, such as sleeving, fillers and coatings may also
be investigated, but use of these options is subject to Design Authority approval.

Procedure for Weld Repair


a.

All weld repairs are to be carried out in accordance with Defence Standard 02-771.
Where deep excavation is necessary the preparations for the weld repair should be
angled to the surface whilst at the same time ensuring that the size of the repair is
kept to a minimum. The potential corrosion path is through the HAZ and by angling
the weld boundary, a longer corrosion path is provided.

b.

Defence Standard 02-771 requires heat treatment of castings after weld repair, in
order to minimise HAZ corrosion. The Design Authority may waive this when
appropriate.

Inspections
a.

A complete record of the weld repairs carried out is to be added to the Weld Repair
Recording Sheet as per the requirements of Part 2 of this Defence Standard.

b.

Reclaimed castings are to be fully inspected as per the requirements of Defence


Standard 02-747 Part 2 or 4.

Re-Stamping
a.

The suitably experienced person witnessing the stamping is to sign the Revalidation
Certificate. A line is to be stamped through the previous validation date and the new
date stamped as a suffix to the original number. Where a weld repair has been made
on a casting that has not previously been weld repaired then the letter 'A' is to be
stamped as a prefix to the radiographic number.
17

DEF STAN 02-872 Pt 3 / Issue 1

NOTE: Pressure castings are not to be stamped on the highly stressed region e.g. Critical
Test Regions of the castings. The stamping should be positioned on low stress areas as
indicated below:
i. Valve bodies - should be stamped at the edge of the cover flange or in the absence
of a prominent flange then as close to the cover position as possible. Failing this
another flange should be stamped, but stamping on hull flanges is to be avoided.
ii. Flange fittings - to be stamped on a flange edge.
iii. Unflanged fittings - to be stamped on an area that is thicker that the minimum
acceptable wall thickness.
5.6

Certification
a.

5.7

On completion of the examination and weld repairs, a Revalidation Certificate is to


be completed in the format of Annex E.

Records
a.

A copy of the Revalidation Certificate, QA certificate of compliance and the full QA


records, as listed in Annex F, are to accompany the casting. These are to be held by
the Through Life Records Contractor when the casting is fitted to the vessel, and are
to be available for future revalidations.

18

DEF STAN 02-872 Pt 3 / Issue 1


ANNEX A.
RELATED DOCUMENTS
A1.

The following documents and publications are referred to in this Defence Standard:

JSP430

MOD Ship Safety Management System Handbook

Def Stan 02-341

Requirements for cleaning of items components and equipment for fluid


systems
Requirements for Nickel Aluminium Bronze Castings and ingots

Def Stan 02-747

Part 1 - Nickel Aluminium Bronze (Naval alloy) centrifugal castings and


ingots
Part 2 - Nickel Aluminium Bronze (Naval alloy) sand castings and ingots

Def Stan 02-824

Part 4 - Nickel Aluminium Bronze (Naval alloy) sand castings with


welding restricted to the non-wetted surface (Class I and II castings only)
Requirements procedure and inspection for weld repair of copper alloy
and nickel alloy castings
Copper Nickel Chromium sand castings and ingots

Def Stan 02-872

Procedure for First Level Nickel Aluminium Bronze Castings

Def Stan 02-771

Part 1 - Policy
Part 2 - Validation
Def Stan 68-188
Def Stan 80-20

Part 4 - Inspections Outside of Long Overhaul Period


Emulsifier for solvent cleaner

DGS 8520

Cleaning compound, solvent, cold bath type, for metal (cresylic acid/
dichloromethane)
Cast Nickel Aluminium Bronze (Superseded by Defence Standard 02747 part 2)
Cast Nickel Aluminium Bronze (Superseded by DGS 348)

SSP 25

Quality Assurance for Safety in Submarines

DGS 348

19

DEF STAN 02-872 Pt 3 / Issue 1


ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B1.

For the purposes of this Defence Standard the following definitions and abbreviations
apply:

Design Authority

Authority within MOD with design responsibility for the equipment

DDIN

Departure from Design Intent

FEA

Finite Element Analysis

First Level Quality


Assured

HAZ

Where the consequences of failure of a hull area, system or equipment


are such that it would lead to loss of the submarine, these areas, systems
and equipment's will be classified First Level and additional Quality
Assurance measures will be implemented. SSP 25 refers.
Heat Affected Zone around a weld.

NAB

Nickel Aluminium Bronze to DGS 8520, DGS 348 or Def Stan 02-747

NAB Register

NDE

The document used to monitor and control the inspection and


replacement of First Level Quality Assured NAB castings which are
normally in contact with sea water and are fitted on HM submarines
MOD in-house code for determining the life of NAB castings based on
statistical analysis
Non Destructive Examination

NSN

NATO Stock Number

QA

Quality Assurance

LOP(R)

Long Overhaul Period(Refuel). This replaces the obsolete term refit.

LOP(R) Contractor

Organization contracted to carry out the LOP(R) of the submarine.

Revalidation

Examination of used NAB castings during their life to the requirements


of this Part of this Defence Standard to determine the castings fitness for
further service
Organization contracted to carry out the revalidation of the castings

NABWETLIFE

Revalidation
Contractor
RVI

Remote Visual Inspection

Through Life Records Organization contracted to maintain the QA records for NAB castings
Contractor
through life
Validation
Examination of new NAB castings prior to fitting in critical positions to
the requirements of Part 2 of this Defence Standard
ZIPSCAN
Proprietary time of flight ultrasonic examination technique developed by
AEA which has been used for the detection of selective phase corrosion

20

DEF STAN 02-872 Pt 3 / Issue 1


ANNEX C.
PROCUREMENT CHECK LIST
Notes:
C.1
This check list is to ensure that certain aspects of this Naval Engineering
Standard are consulted when preparing a Procurement Specification for a
particular application.
C.2

Clauses where a preference for an option is to be used or where specific data is


to be added are included in the Check List.

C.3

Each item is to be marked either:


= included
NA = not applicable

CHECK
No.

CLAUSE
No.

CHECK

21

or
NA

DEF STAN 02-872 Pt 3 / Issue 1

ANNEX D.
CASTING RECORD OF REVALIDATION INSPECTION
Revalidation Date

Material

Casting Unique Radiographic


Number

Previous Radiographic No. (if


different)

Component Description
1
Defect
ID No

22

Radiograph
Type of
position
Defect
numbers for
e.g. HAZ,
weld repairs
Plug,
(see previous
QA documents) O Seal

4
Defect
Length
(mm)
A

Defect Depth (mm) Defect Free


Wall
Thickness
Ultrasonic Etch &
(mm)
Grind

10

Remaining
Wall
Thickness
(mm)

Drawing
Wall -10%
(mm)

D>E =

D=(C-B)

Action:
Accept,
Reject,
Refer to Design
Authority

D<E = x

Completed by .................................... Date ...................

DEF STAN 02-872 Pt 3 / Issue 1

ANNEX E.
REVALIDATION CERTIFICATE FOR NAB CASTINGS
PART I - IDENTIFICATION
A.

EQUIPMENT SERIAL No.

F.

PIL No (VSN/

B.

UNIQUE RADIOGRAPH No.

G.

PIL LINE ENTRY No

C.

COMPONENT DRAWING No.

H.

COMPONENT ADREFNO

D.

SHIP FITTING No. (e.g. BS 123)

I.

MANUFACTURER

E.

COMPONENT DESCRIPTION

MATERIAL
SPECIFICATION

PART II - REVALIDATION ACTION

Signature

A.

ALL PREVIOUS CONCESSIONS ASSESSED

B.

CLEANED ETCHED AND GROUND TO DETECT CORROSION

C.

THICKNESS RECORDS IN WAY OF CORRODED AREAS ATTACHED

D.

CASTING RECORD OF REVALIDATION INSPECTION TABLE COMPLETED FOR


ALL DEFECTS AND ATTACHED WITH SKETCH.

PART III - RECLAMATION AND REVALIDATION


A.

PREVIOUS VALIDATION DOCUMENTATION SCRUTINIZED

B.

SUBSEQUENT WELD REPAIR

C.

COMPONENT RADIOGRAPHED AND DP EXAMINED

D.

DIMENSIONAL CHECKS

E.

WELD AREAS RE-MACHINED

F.

INTERNAL WELD REPAIRS

Indicate action taken by signature (or NA if not applicable in appropriate box).


CONCESSION NOS
CONCESSIONS GRANTED FOR ABOVE COMPONENT
I certify that the above NAB casting has been revalidated in accordance with Def Stan 02-872
Part 3 and stamped *
SIGNATURE
NAME IN BLOCK LETTERS
AUTHORITY/DEPT
DATE
* CASTING IDENTIFICATION TO BE INSERTED

23

DEF STAN 02-872 Pt 3 / Issue 1

ANNEX F.
CHECK LIST FOR DOCUMENTS
REVALIDATED CASTINGS
F.1.

TO

BE

INCLUDED

IN

QA

PACK

FOR

All certification and record sheets for the revalidated castings are to be annotated with the
appropriate ship fitting number or pump serial number (as applicable), description, and
unique radiographic number.

QA CERTIFICATE OF COMPLIANCE
CHEMICAL ANALYSIS RESULTS RECORD SHEET
MECHANICAL TESTS RESULTS RECORD SHEET
VISUAL INSPECTION RESULTS RECORD SHEET
LIQUID PENETRANT RESULTS RECORD SHEET
RADIOGRAPHY/ULTRASONIC RESULTS RECORD SHEET
HEAT TREATMENT CERTIFICATE
PRESSURE TEST RESULTS RECORD SHEET/ CERTIFICATE OF COMPLIANCE
GRIDDED SKETCH FOR WALL THICKNESSES
WALL THICKNESS RECORDING SHEET CROSS-REFERENCED TO GRIDDED
SKETCH
SKETCH/PHOTOGRAPH OF WELD REPAIRS
WELD REPAIR RECORDING SHEET CROSS-REFERENCED TO SKETCH/
PHOTOGRAPH
REVALIDATION CERTIFICATE
CASTING RECORD OF REVALIDATION INSPECTION TABLE
All QA records complete:

SIGNATURE
NAME IN BLOCK LETTERS
AUTHORITY/DEPT
DATE

24

DEF STAN 02-872 Pt 3 / Issue 1

ALPHABETICAL INDEX
(Note: Page Numbers are given)

NAB Register 8, 10
NABWETLIFE 15

Ardrox 160 5, 10, 12

Biofouling 10, 12

Photographs 10, 12
Probabilistic approach 15

Casting
Copper Nickel Chromium 8, 15
Nickel Aluminium Bronze 2, 8
Rejected 10, 15, 17
Certificate
Revalidation 8, 15, 17, 23, 24
Validation 8, 16
Concessions 8, 10, 23
Corrosion
Crevice 10, 12
HAZ 10, 12, 17
Plug 10, 12
Selective Phase 2, 8, 10, 12

Quality Assurance Documentation 8, 12

R
Radiograph 8, 15
Redeposited copper 10, 12, 15
Revalidation Contractor 8

S
Silver Nitrate 5, 12
Sketches 8, 12

Design Authority 2, 8, 10, 12,


15, 17
Deterministic approach 15
Drawings 8, 12, 15

Through Life Records Contractor 15, 16, 17

U
Ultrasonic Examination 12

Etching 10, 12

Validation 2, 8

FEA 12, 15
Ferric Chloride 10

Wall Thickness 2, 8, 12, 15


Weld map 8
Weld repairs 17

H
Heat Treatment 8, 17

ZIPSCAN 8, 12

Identification number 12

L
Life assessment 15
LOP(R) Contractor 8

25

DEF STAN 02-872 Pt 3 / Issue 1

(Intentionally left blank)

26

Inside Rear Cover

Crown Copyright 2002


Copying Only as Agreed with DStan

Defence Standards are Published by and Obtainable from:


Defence Procurement Agency
An Executive Agency of The Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW G2 8EX

DStan Helpdesk
Tel 0141 224 2531/2
Fax 0141 224 2503
Internet e-mail enquiries@dstan.mod.uk

File Reference
The DStan file reference relating to work on this standard is D/DStan/69/02/872 Pt 3.
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a
Defence Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by up issue or amendment. It is important that users of
Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards is contained in Def Stan 00-00 Standards for Defence Part 3 ,
Index of Standards for Defence Procurement Section 4 Index of Defence Standards and Defence
Specifications published annually and supplemented regularly by Standards in Defence News (SID
News). Any person who, when making use of a Defence Standard encounters an inaccuracy or
ambiguity is requested to notify the Directorate of Standardization (DStan) without delay in order
that the matter may be investigated and appropriate action taken.